Basket and process for dyeing textile materials

ABSTRACT

Dyeing basket comprising a substantially cylindrical storage body ( 1 ) having a preset height, with an upper base (U) and a lower base (L), within which the material ( 2 ) to be dyed is disposed, the body ( 1 ) being perforated, characterized in that, close to the upper base of body ( 1 ), at a preset distance (da) from the longitudinal axis (x-x) of the latter, provision is made for two opposite journals ( 30 ) intended for supporting a reel or drum ( 4 ), rotating freely about the common axis (y-y) of said journals, the said journals ( 30 ) being at a preset distance (ds) from the upper base (U) of body ( 1 ), so that the whole surface of drum ( 4 ) will result below the same base (S).

[0001] The present invention relates to a basket and process for dyeing textile materials.

[0002] It is known to those skilled in the art that the process of dyeing textile materials can be carried out by deeping the materials into solutions of colouring substances or dyeing baths held in suitable tanks.

[0003] The operations for dyeing textile materials of woven or knitted type and the like, are generally perfomed by using machines operating “in string”. More specifically, this known tecnique includes sewing the material to be treated to form a loop. Thus arranged, the material is made to circulate inside the dyeing tank by means of suitable devices ensuring the movement thereof in contact with the relevant bath. The introduction of the material into the machines is carried out by hand with the machines brought to a halt; accordingly, the production stops over the whole time necessary to complete the operations for the loading and unloading thereof.

[0004] The main object of the present invention is to propose a basket intended for containing textile materials, and a process for dyeing the textile materials, said basket and process, by leaving the steps for the physical and chemical transformations related to the very dyeing substantially unchanged, allow a drastic reduction of dead times connected to the machines' loading and unloading.

[0005] This result has been achieved, according to the invention, by providing an apparatus and an operating process having the characteristics indicated in the independent claims. Further characteristics being set forth in the dependent claims.

[0006] The present invention makes it possible to dispose a plurality of baskets, holding the materials to be dyed, upon a standby or parking plane to allow the removal and handling thereof by suitable means, thereby offering a major contribution over the automation of dyeing processes and a drastic reduction of dead times. Moreover, a basket according to the invention is easy to make, cost-effective and reliable even after a prolonged service time.

[0007] These and other advantages and characteristics of the invention will be best understood by anyone skilled in the art from a reading of the following description in conjunction with the attached drawings given as a practical exemplification of the invention, but not to be considered in a limitative sense, wherein:

[0008]FIGS. 1A, 1B abd 1C show, respectively, a basket in longitudinal section view, with nozzle for supplying the dyeing bath, as viewed over the upper base of the basket, and two enlarged details of FIG. 1A in plan view (FIG. 1B) and in perspective view (FIG. 1C);

[0009]FIGS. 2A and 2B are, respectively, two views in orthogonal section to each other of a dyeing basket according to a further embodiment of the invention;

[0010]FIG. 3A shows schematically a dyeing tank having inside the basket shown in FIG. 1A;

[0011]FIG. 3B shows schematically a dyeing tank having inside the basket shown in FIG. 2B;

[0012]FIGS. 4A and 4B are two orthogonal views of a dyeing tank;

[0013] FIGS. 5A-5G shows schematically a sequence of steps related to the positioning of a basket of a type shown in FIG. 1A within a tank of a type shown in FIG. 3A;

[0014] FIGS. 6A-6G shows schematically the positioning of a basket of a type shown in FIG. 2A within a tank of a type shown in FIG. 3B;

[0015]FIGS. 7A and 7B show an enlarged detail of the baskets driving system upon engagement (FIG. 7A) and release (FIG. 7B) of a basket;

[0016]FIG. 8 shows a further embodiment of a dyeing basket according to the invention;

[0017] FIGS. 9A-9C are two orthogonal views of a basket according to a further embodiment thereof (FIGS. 9A and 9B), and a view of such basket within a dyeing tank (FIG. 9C);

[0018]FIG. 9D shows the tank and basket of FIG. 9C and relevant systems for the supply of the tank and the movement of reel (4).

[0019] Reduced to its basic structure, and reference being made to the figures of the attached drawings, a dyeing basket according to the invention comprises a substantially cylindrical storage body (1) having a preset height, with an upper base (U) and a lower base (L), within which a roll (2) of the material be dyed is disposed. The body (1) is a perforated metal sheet. Fastened in the vicinity of the upper base of body (1), at a preset distance (da) from the longitudinal axis (x-x) of the latter, is a bracket (3) having two opposite journals intended for supporting a reel or drum (4) rotating freely about the common axis (y-y) of said journals. The said journals (30) are at a preset distance (ds) from the upper base (U) of body (1), so that the whole surface of drum (4) will result below the same base (U). Also advantageously, provision is made for a sheet (5), fastened to the inner side surface of body (1), which sheet allows keeping suitably spaced apart the edges of the material (2) closer to the drum (4). The material (2) to be dyed is loop-like closed (by a temporary sewing performed by an operator) over the cylinder (4), so that the material will result outside the sheet (5) and passing through the ring (50) located rearwardly of the drum (4), and preferably far lower with respect to the latter, said ring making up a guiding and centering element of the material (2) with respect of the drum (4).

[0020] According to the embodiment shown in FIGS. 1A-1C of the attached drawing, the drum (4) has a plurality of surface reliefs, both in correspondence of the central body and in correspondence of the right and left frusto conical bases (40), to allow the movement of same drum about said axis (y-y) as a consequence of the jet of liquid dye delivered from a nozzle (6) located thereabove (FIG. 1B). The said nozzle (6), which may be a triple one as shown in FIG. 1B so that the jet delivered therefrom is able to hit both the central body of the drum (4) and the bases (40), can be mounted on the lid (70) of a tank (7) wherein the basket is immersed, as will be better explained later. In practice, the jet delivered by the nozzle (6) hits the surface reliefs of drum (4) by causing it to rotate about the axis (y-y) and thus causing the material (2) to be driven along by the central body of the same drum upon which the material (2) is supported. Said driving of the material (2) entails the cyclical immersion and emersion of each part thereof into and out of the dyeing bath (D) throughout the time during which the jet is delivered from the nozzle (6).

[0021] As illustrated in FIG. 3A, the tank (7) into which the basket (1) cointaining the material to be dyed (2) is inserted, is provided with a lid (70) connected with the upper base of the tank by a hinge (71) having horizontal axis, and engaged with an actuator (72) which drives it into rotation about the axis of said hinge, in the opening direction to allow the introduction of the basket within the tank, and in the closing direction to start the dyeing process inside the same tank. As illustrated also in FIGS. 4A and 4B of the attached drawings, the actuator (72) is connected with the lid (70) by means of a fork structure comprising two parallel arms (73) which, at one end, are hinged on the body of tank (7) by a hinge (79) and, at the opposite end, are joined with each other by a crosspiece (74). At a point below the crosspiece (74) the said arms (73) are connected with the lid (70) by a lever (75) which, on one side, is connected with the arms (73) by a hinge having horizontal axis (76) and, on the other, is connected with an appendix (77) of lid (70) by a further hinge link (78). The axes of said hinges (71, 79, 76, 78) are all parallel to each other. Fixed on the lid (70) of tank (7) is the nozzle (6) being fed with liquid through a corresponding flexible hose (60) connected with a circuit for the recirculation of the dyeing bath (D), said circuit comprising a pump (61) which draws the bath from the bottom of the tank (7) via a conduit (62) and put it again in circulation via a conduit (63) leading to the hose (60). The hose (60) can be disposed for passing through a cooling battery (M) and, respectively, through a battery for the thermal exchange heating(N) of the fluid. The said batteries (M, N) are of a type known to those skilled in the art and will not be described in greater detail.

[0022] According to the embodiment shown in FIGS. 2A and 2B of the attached drawings, the movement of the material (2) inside the basket is achieved by delivering a jet of colouring liquid within a conduit (8) which leads into a funnel element (80) through which the material (2), still loop-closed on the drum (4) is disposed. By virtue of the velocity of the jet delivered via the conduit (8) and exiting from the discharge section (81) of element (80), the material (2) results driven forward (arrow F) by being in contact with the central body of drum (4) freely rotating about the said axis (y-y). Again, the cyclic immersion and emersion of any part of the material (2) into and out of the dyeing bath (D) take place over the whole of jet's delivery time.

[0023] The diagram of FIG. 3B is substantially identical to that of FIG. 3A, with the exception that, on one side, the pump (61) for the recirculation of the dyeing bath draws the bath out of the tank (7) and, on the other, causes it to recirculate through the conduit (82) which is an extension of conduit (8) leading into the element (80).

[0024] In order to automate the dyeing process, use can be made of a mechanical arm (9)—known per se to those skilled in the art—able to draw the baskets (1) from a standby plane (Q) in order to dispose them inside a tank (7) and, upon completion of the dyeing cycle, to remove them from the tank and dispose them onto the same plane (Q) or a different plane (for example, one receiving baskets with materials being treated). The said arm (9) is provided at the bottom with a grip section (90) intended for engaging a top appendix (11) of basket (1) during the hooking thereof, and disengaging it upon a release step. As illustrated in FIGS. 7A and 7B of the attached drawings, the said grip section (90) of arm (9) comprises a bush with lead-in mouth (91) to be fitted onto the said appendix (11) upon the hooking step, with an intermediate cylindrical portion and a rear conical portion followed by a further cylindrical portion. The bush (91) receives a plurality of balls (92) onto which a spring (93), also housed inside the rear cylindrical portion of the same bush (91), is made to act from above. Acting on the spring (93) is a lever (94) which is operated by a pneumatic actuator (95) mounted on the same arm (9), that is, engaged with a corresponding support bracket (96). When the lever (94) is in horizontal position, as shown in FIG. 7A, the spring (93) causes the balls to press the corrugated surface of appendix (11) exhibetd by the basket (1). On the other hand, when the lever (94) is rotated upwards, as in FIG. 7B, the balls (92) are no longer acted upon by the spring (93) and, as a consequence, the said appendix is released. In practice, upon hooking a basket (1), the unit (90) takes up the configuration of FIG. 7A. Upon the release of the basket, the unit (90) takes up the configuration of FIG. 7B. The said arm (9) is mounted on a movable support (97) allowing the positioning of same arm (9) and thus of the engagement/disengagement unit (90) in correspondence of the resting sites of baskets (1) and in correspondence of tank (7). The said movable support (97) is engaged with electric motors (not shown) by using connection means of known type, said motors being in turn engaged with a programmable control unit also of known type and which operates the actuator (72) for causing either the opening/closing of the tank's lid (70), upon the arrival of baskets (1) during the loading step, or the removal thereof during the unloading step, that is upon completion of the dyeing.

[0025] The diagram of FIGS. 5A-5G relates to the movement of a basket such as the one shown in FIG. 1A.

[0026] The diagram of FIGS. 6A-6G relates to the movement of a basket such as the one shown in FIGS. 2A and 2B.

[0027] In practice, an operating process according to the present invention includes loading the materials to be treated into perforated baskets, that is, baskets which are permeable to the bath, prior to dispose the same baskets inside the bath-holding tank. The baskets with the material to be treated are stationed at known and preset points of a parking structure and each of them is removed therefrom to be introduced within a dyeing tank. Upon completion of the dyeing, each basket is withdrawn from the tank where it was introduced, to be positioned in correspondence of the starting point or other point of the plant where the discharge, that is, the removal of the textile material from each basket, will take place. The number of baskets for each dyeing tank is made to vary according to contingent work requiremnets. While the various tanks of the system operate the treatment of the material held in the baskets previously introduced therein, the various baskets located in the parking area can be loaded with other material to be treated or, if they contain material already treated, to be unloaded, that is, emptied out of their relevant content. In this way, the utilization of the system is optimized by reducing the dead times to a minimum, especially when considering that the driving of the baskets can be fully automated as set forth above. Unattended works can be carried out by producing and storing programs, for example, during night time or non-working days.

[0028] The example in FIG. 8 entails driving the material (2) along by a jet of compressed air delivered into the said funnel element (80). The compressed air is produced by a compressor (64) provided with a conduit (65) which connects the outlet of the compressor to the funnel (80), and with a conduit (66) which connects an outlet mouth of tank (7), located close to the upper base of the latter, to the inlet section of the compressor. The circulation of the dyeing bath is ensured by the pump (61) which draws the liquid out of the base of tank (7) via the conduit (62) and puts it again in circulation from above the tank (7) via the conduit (63) passing through the exchangers (M, N), and via the hose (60) and the nozzle (6), the latter being located on the lid (70) of tank (7). According to this exemplary embodiment of the present invention, therefore, there are provided a circuit (61, 63, 62) for the circulation of the dyeing bath, and a circuit (64, 65, 66) for the compressed air which causes the material inside the tank to be moved. In this way, it is possible ensuring a higher drive velocity of the material inside the tank while using a reduced quantity of dyeing liquid.

[0029] The basket shown in FIGS. 9A-9D of the attached drawings differs from those previously described for exhibiting a different system for the movement of reel (4). More particularly, this basket comprises means for driving the reel (4) into rotation about its axis (y-y) and means for driving the reel (4) into rotation about the longitudinal axis (x-x) of basket (1). According to the example illustrated in FIGS. 9A-9D of the drawings, the means for driving the reel (4) into rotation about its longitudinal axis comprise a shaft (41) passing, inside a corresponding tubular hinge (410), longitudinally and centrally within the basket (1), the lower end of said shaft (41) being connected to a power takeoff (411) to be mated with a corresponding pin (412) passing centrally through the lower base of the tank (7) and engaged with a motor-reducer (413) The upper end of shaft (41) carries a bevel gear (42) which meshes with a an orthogonal bevel gear (43) keyed on the shaft (430) whose axis coincides with the one (y-y) of reel (4), the latter being mounted longitudinally onto the shaft (430) at a preset distance from the vertical central shaft (41). In practice, the rotation of shaft (41) implies the rotation of the shaft (430), by means of a bevel gear pair (42, 43), and thus the corresponding rotation of the reel (4) about the respective longitudinal axis (y-y). Again with reference to the illustrated example of FIGS. 9A-9D of the attached drawings, the said means for driving the reel (4) into rotation about the longitudinal axis (xx) of basket (1) comprise a bevel gear (44) and an annular rack (45).

[0030] The gear (44) is keyed onto the shaft (430) on the opposite side of reel (4). The rack (45) is fixed to the inner wall of basket (1) and lies in a plane orthogonal to the longitudinal axis (x-x) of the latter. The said shaft (430) goes through a corresponding spherical support (431), of a type available on the market, which is suspended to the central grip appendix (11) of the basket (1) via an idle joint (433). The centering ring (50) is fixed to the outer casing (rotating about the axis x-x) of support (431). The grip appendix (11) is fixed to a frame (111) of basket (1) in correspondence of the upper base of the latter (in a manner similar to that described for the previous examples and with reference to FIGS. 1A, 2A, 2B, 5A-5G, 6A-6G). In practice, the rotation of shaft (41), by entailing the rotation of shaft (430), determines the corresponding rotation of gear (44) and, therefore, the rolling of the latter onto the rack (45) solid to the stationary, that is, non-rotating, basket (1). In this way, there is obtained the rotation of shaft (430), and thus of reel (4), about the longitudinal xis (x-x) of the basket (1).

[0031] The speed (V) of gathering the material (2) can be changed by changing the ratio of the gear (44) and the diameter (d) of the reel (4), also by keeping the rotary speed of shaft (430) constant about the axis (x-x).

[0032] With reference to the drawing of FIG. 9B, “V” indicates the speed of lifting or gathering the material (2), and “−V” indicates the speed of falling back thereof by virtue of the movement operated by the reel (4) which rotates about its longitudinal axis. The direction of rotation of shaft (430) about the axis (x-x) of basket (1) is opposite to the direction of rotation of the reel (4) about the relevant axis (y-y). This allows eliminating any drive tension in the material (2), that is, it allows suppressing the relative velocity of each point of the material (2) with respect to the inner wall of the basket (1), so that the material being treated is not subjected to rubbings. It results thus possible to effectively treat also particularly delicate materials. As illustrated in the drawings of FIGS. 9C and 9D, the distribution of the dyeing bath inside the tank (7) is ensured by a plurality of nozzles (6) connected to each other by a manifold (601) via a supply conduit (60) which is in turn connected to a supply plant (61, 62, 63, M, N) of a type previously described and associated with the inner face of lid (70) of tank (7). This solution makes it possible to fully spraying the material (2) under treatment. 

1) dyeing basket comprising a substantially cylindrical storage body (1) having a preset height, with an upper base (U) and a lower base (1), within which the material (2) to be dyed is disposed, the body (1) being perforated, characterized in that, close to the upper base of body (1), at a preset distance (da) from the longitudinal axis (x-x) of the latter, provision is made for two opposite journals (30) intended for supporting a reel or drum (4), rotating freely about the common axis (y-y) of said journals, the said journals (30) being at a preset distance (ds) from the upper base (U) of body (1), so that the whole surface of drum (4) will result below the same base (U). 2) Basket according to claim 1, characterized in that it comprises a sheet (5), fastened to the inner side surface of body (1), which sheet allows keeping suitably spaced apart the edges of the material (2) closer to the drum (4). 3) Basket according to claim 1, characterized in that the material (2) to be dyed is ring-like closed by a temporary sewing, performed by an operator, over the cylinder (4). 4) Basket according to claim 1, characterized in that said drum (4) has a plurality of surface reliefs, both in correspondence of the central body and in correspondence of the right and left frusto conical bases (40), to allow the movement thereof about said axis (y-y) as a consequence of the jet of-liquid dye delivered from a nozzle (6) located thereabove. 5) Basket according to claims 1 and 4 characterized in that the said nozzle (6) is a triple nozzle. 6) Basket according to claim 1, characterized in that it can be positioned inside a tank (7) provided with a lid (70) connected with the upper base of the tank, by a hinge (71) having horizontal axis, and engaged with an actuator (72) which drives it into rotation about the axis of said hinge, in the opening direction to allow the introduction of the basket within the tank, and in the closing direction to start the dyeing process inside the tank, said actuator (72) being connected with the lid (70) by means of a fork structure comprising two parallel arms (73) which, at one end, are hinged on the body of tank (7) by a hinge (79) and, at the opposite end, are joined with each other by a crosspiece (74), at a point below the crosspiece (74) the said arms (73) being connected with the lid (70) by a lever (75) which, on one side, is connected with the arms (73) by a hinge having horizontal axis (76) and, on the other, is connected with an appendix (77) of lid (70) by a further hinge link (78), the axes of said hinges (71, 79, 76, 78) being all parallel to each other. 7) Basket according to claim 1, characterized in that it comprises a funnel element (80) located below said drum or reel (4) and into which a jet of colouring liquid is fed through a corresponding conduit (8). 8) Basket according to claim 1, characterized in that it comprises a funnel element (80) located below said drum or reel (4) and into which a jet of compressed air is delivered. 9) Basket according to claim 1, characterized in that it comprises means for driving the reel or drum (4) into rotation about its axis longitudinal (y-y) and about the longitudinal axis (x-x) of basket (1) at the same time. 10) Basket according to claim 1, characterized in that it comprises a grip appendix (11) to allows for the engagement and movement thereof by automatic drive means. 11) Operating process for carrying out the dyeing of textile materials, characterized in that it includes loading the materials to be treated into perforated baskets, that is, baskets which are permeable to the bath, prior to dispose the baskets inside the tank containing the bath, the baskets with the material to be treated being stationed at known and preset points of a parking structure and each of them being removed therefrom to be introduced within a dyeing tank, upon completion of the dyeing, each basket being withdrawn from the tank where it was introduced, to be positioned in correspondence of the starting point or other point of the plant where the discharge, that is, the removal of the textile material from each basket, will take place. 12) Process according to claim 10 characterized in that, while the various tanks of the system operate the treatment of the material held in the baskets previously introduced therein, the various baskets located in the parking area can be loaded with other material to be treated or, if they contain material already treated, can be unloaded, that is, emptied out of their relevant content. 13) Process according to one or more preceding claims, characterized in that the material held in the baskets is ring-like closed over an element (5) able to suitably space apart opposite edges of materials under treatment and passing through an element (50) for the guiding and centering thereof with respect to a drum or reel (4) idly supported inside the baskets. 